Laminated pad and method of manufacturing

ABSTRACT

A laminated pad and method of manufacturing such pad wherein the laminated pad includes a grip portion and a work surface. The work surface may be comprised of any of a variety of substances including absorbent material, abrasive material, or polishing material. The grip portion may be upstanding for facile gripping with one&#39;s fingers.

BACKGROUND OF THE INVENTION

[0001] The present invention is drawn to a laminated pad and method ofmanufacturing such articles. More specifically, the present invention isa laminated pad having a work surface and a grip portion. The worksurface may be varied, depending upon the desired application, toinclude absorbent, abrasive or polishing components.

[0002] The present invention provides a unique and convenient laminatedpad that may include a pre-selected work surface that is able to performa variety of tasks. For example, present absorbent articles, such ascotton balls, are used for a wide range of applications such as make-upremoval, finger nail polish removal, or product application. However,when absorbent articles of this type are used, often the product beingused or applied may seep through the absorbent article and come incontact with the fingers of the user, thereby creating mess or contactwith the product. Furthermore, it may be difficult to maintain grip on amoistened absorbent article. In the preferred embodiment, the presentinvention is provided with an absorbent work surface, wherein the usualproblems associated with typical cotton type pads are alleviated.

[0003] Alternately, the laminated pad of the present invention may beprovided with an abrasive work surface. Usual abrading devices, forexample for sanding tiny, hard to reach spaces, require power sanders ofreduced size or inconvenient wadding of abrasive material, while thepresent device, supplied with an abrasive work surface, allows facileuse while abading hard-to-reach surfaces. A further embodiment of thelaminated pad includes a polishing work surface to be used for polishingdifficult areas or in any application that the user requires aninexpensive, disposable polishing pad.

[0004] In the preferred embodiment of the invention the laminated padincludes an absorbent work surface, and a finger grip area including abarrier portion. The finger grip area is located opposite the worksurface and includes a barrier portion for preventing moisture from thework surface from reaching the fingers of the user. The method ofmanufacturing and apparatus utilizing the method are also presented. Themethod and apparatus are capable of quickly and accurately producing thenovel article in a number of sizes and shapes.

SUMMARY OF THE INVENTION

[0005] The present invention resides in a laminated article and methodand apparatus for the manufacture of the article. The article includes afirst layer having a work surface, with the first layer adhesivelybonded to a moisture resistant gripping and barrier portion. The worksurface may be of a variety of materials, including but not restrictedto, absorbent, abrasive or polishing materials.

[0006] The novel method of manufacture may be used in connection with anovel arrangement of machine components. The steps of the method ofmanufacture include: providing a continuous web of material having awork surface and an oppositely adjacent supporting surface material;folding the first web of adhesive-backed material along twopredetermined folding areas located longitudinally coextensive thematerial length to form two longitudinally coextensive folded edges,wherein each of the exposed surfaces are preferably adhesively coated;providing a second continuous web of adhesive-backed material;overlaying and coupling the second adhesive-backed material to a firstside of the first, folded adhesive-backed material length; coupling thesupporting surface of said continuous web of work surface material to asecond side of the first, folded adhesive-backed material length to forma layered web; and die cutting the layered web into a predeterminedconfiguration. Optionally, a continuous strip of carrier material forsupporting the web of material having a work surface may be provided.

DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1a is a perspective view of the preferred embodimentlaminated pad made according to the present invention.

[0008]FIG. 1b is a perspective view of an alternate embodiment laminatedpad showing a square configuration.

[0009]FIG. 1c is a perspective view of another alternate embodimentlaminated pad and showing a triangular configuration.

[0010]FIG. 1d is a perspective view showing a plurality of linkedtogether laminated pads.

[0011]FIG. 2 is a top plan view of the laminated pad shown in FIG. 1.

[0012]FIG. 3 is a side elevational view of the laminated pad of FIG. 1.

[0013]FIG. 4 is a side elevational view of the laminated pad shown inFIG. 3, but with the pad rotated 90 degrees from the view of FIG. 3.

[0014]FIG. 5 is a schematic diagram showing the components of thepresent invention being fed into a machine suitable to perform theprocess and make at least one of the products disclosed herein.

[0015]FIG. 6 is a perspective view showing the general relationship ofthe components for making the various embodiments disclosed herein andtaken from the area designated generally by the numeral 6 in the view ofFIG. 5.

[0016]FIG. 6a is a perspective view showing the general relationship ofthe components for making the various embodiments disclosed herein andtaken from the area designated generally by the numeral 6 a in the viewof FIG. 5.

[0017]FIG. 7 is a cross sectional view of the various layers comprisingthe laminated pad, but prior to cutting, and taken along lines 7-7 ofFIG. 5.

[0018]FIG. 8 is a cross sectional view of a section of the cutting tooland various layers comprising the laminated pad and taken along lines8-8 of FIG. 5.

DETAILED DESCRIPTION

[0019] Although the disclosure hereof is detailed and exact to enablethose skilled in the art to practice the invention, the physicalembodiments herein disclosed merely exemplify the invention which may beembodied in other specific structure. While the preferred embodiment hasbeen described, the details may be changed without departing from theinvention, which is defined by the claims.

[0020] The present invention is directed to a method, apparatus, and astructure resulting from the method and apparatus. The present inventiongenerally relates to laminated pads 10, and more particularly, tolaminated pads 10 having a variety of work surfaces 14. The method ofthe present invention, while unique and fully described herein, may beused on novel machine components and cooperating arrangements thereof.

[0021] The advantages of the present invention are believed not to beapparent from the known pads and work surfaces of the prior art. As seenin FIGS. 1a-4, the laminated pad 10 of the present invention typicallyincludes a first layer 12 having a work surface 14 and a support surface16, and a second layer 18 adhesively attached to the support surface 16of the first layer. As seen particularly in FIGS. 1a and 3, the secondlayer 18 is comprised of two adjacent portions 20 a and 20 b, which areeach divided into a supporting area 22 folded at 24, and an upstandingarea 26. The upstanding area 26 of each adjacent portion 20 a, 20 b isadhesively coupled to the other upstanding area 26 to provide a grippingportion 28.

[0022] Referring to FIG. 3, an elevational edge view of the laminatedpad 10, including the gripping portion 28, may be seen. It may be notedthat in the preferred embodiment the gripping portion 28 may be slightlyoffset from center to provide a larger supporting area 22 on one half ofthe pad 10 to accommodate more facile gripping of the pad 10.

[0023] Referring to FIGS. 1a-d and 3, the second layer 18 is folded, asshown at 24, to form an upstanding gripping portion 28. In the preferredembodiment the second layer 18 may be bipartite and comprise twoadjacent portions 20 a and 20 b which each respectively fold at 24 andform adjacent upstanding areas 26. Conjoined upstanding areas 26 formthe gripping portion 28.

[0024] In the preferred embodiment, the work surface 14 may befabricated from a prelaminated absorbent material including componentssuch as Delnet AC530NA facing material and Rayon substrate, as in thecase of a makeup removal pad. Another embodiment of the laminated pad 10may include a work surface 14 having a polishing characteristic. Afurther embodiment of the laminated pad 10 may include a work surface 14made of an abrasive material, for example, an abrasive surface such assandpaper or a material similar to “steel wool”. Alternately, the worksurface 14 may comprise a lint-free material such as a sponge.

[0025] The second layer 18 is preferably formed of sheet polypropylene,acetate or any other flexible material capable of retaining an adhesivecoating on at least one side. Currently it is preferred to use anadhesive coated polyester. Products suitable for this application may becommercially obtained from any pressure sensitive tape manufacturure,such as for example, 3-M Corporation. The adhesive coating is preferablypre-applied although it is within the province of this invention to usean uncoated web material that may be adhesively coated in situ duringmanufacture.

[0026] It is to be understood that the laminated pad 10 of the presentinvention may be cut into any size or shape as illustrated in FIGS. 1a,1 b and 1 c by way of example. A varied pad 10 shape allows use indiverse application environments when, as an example, a corner shapesuch as that shown in FIG. 1c, may aid the user in reaching a similarlyconfigured work site. Further, it is within the scope of this inventionto couple a plurality of pads 10 together with a connecting band 29, asshown in FIG. 1d.

[0027] One possible method for achieving the structure of FIGS. 1a-4 isthe use of a novel machine and method in which the first and secondlayers are assembled and cut into a desired configuration. (See theschematic view of FIG. 5 for a general illustration of the relationshipof the components of the machine). In particular, referring to FIGS. 5,6, and 6 a, the method by which the laminated pad 10 is manufactured isshown. This method includes feeding the first layer 12 from a roll 30supported by a journal 32 over a predetermined number of rollers andtoward the cutting structure 60. A supporting carrier strip 34 is fedfrom a roll 31 supported by a journal 33 and over a predetermined numberof rollers and passes colinearally and underlying the first layer 12. Afirst continuous web 36 of material to be used in forming the secondlayer 18 is fed from a roll 35 supported by a journal 37 and over apredetermined number of rollers toward a folding apparatus 40. The firstweb 36 is preferably adhesively coated on one side 38. The foldingapparatus 40, seen particularly in FIG. 6, turns the sides of the firstweb 36 upwardly and onto itself to form two longitudinally coextensivefolded edges 41.

[0028] Seen particularly in FIG. 6, the folding apparatus 40 preferablycomprises a first rotatable drive shaft 42 having two spacers 44 presetto approximate the width of the incoming first web 36, and a secondrotatable drive shaft 46. The second rotatable drive shaft 46 includes apair of spacers 48 preset to force the edges of the web 36 upwardly andover itself to form a pair of folded edges 41.

[0029] Again with reference to FIG. 6, it can be seen that a secondcontinuous web 50 is fed from a roll 51 supported by a journal 53 andover a predetermined number of rollers toward the folded first web 36.The second continuous web 50 is preferably adhesively coated on one side52. As the second web 50 meets the folded first web 36, an anvil roller54 presses the adhesive sides towards one another to conjoin the first,folded web 36 and the second web 50 together to form the second layer18. The anvil roller 54 further presses the formed second layer 18 tothe first layer 12. The first layer 12, riding on the supporting carrierstrip 34, is composed of a work surface 14 and a support surface 16. Thesecond layer 18, formed from the first, folded web 36 and the second web50, is pressed to the support surface 16 of the first layer 12 with thework surface 14 of the first layer 12 facing the carrier strip 34.

[0030] Referring now to FIG. 6a, it will be observed that the compositearticle 56 (seen in cross section in FIG. 7) comprising the conjoinedfirst layer 12 and second layer 18 is fed toward a die cutting tool 60.As seen in FIG. 8, the die cutting tool 60 severs the layers 12 and 18with each folded edge 41 approximately located at the center of thepreconceived shape. The cut may be located slightly off center toprovide a larger protective barrier or support area 22 on one side. Thedie cutting tool 60 preferably includes a plurality of pre-configuredcutting knives 58, shown here as circular. With further reference toFIG. 6a it is seen that the cut laminated pads 10 are fed from thecutting tool 60 to a chute 62, and thereafter packaged.

[0031] Anvil roll 64, supported by rotating shaft 66 acts to pull thescrap material 68 from the cutting area for disposal. As shown in FIGS.6a and 8, the carrier strip 34 is not pierced, but after cutting of thepads 10, is separated from the scrap material 68 on a roll 70 (seen inFIG. 5) to be cleaned and reused. While it is preferred that the methodincludes use of a carrier strip 34 as stated above, it is to beunderstood that the present method may be practiced without the carrierstrip as well.

[0032] It will be apparent that the described invention provides alaminated pad 10 that includes a work surface 14 which may be abrasive,absorbent or otherwise and further includes a second layer 18 havingsupporting areas 22 which provide a convenient barrier means to protecta user of the pad 10 from unwanted contact with any products used withthe pad 10.

[0033] The foregoing is considered as illustrative only of theprinciples of the invention. Furthermore, since numerous modificationsand changes will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described. While the preferred embodiment has been described,the details may be changed without departing from the invention, whichis defined by the claims.

What is claimed is:
 1. A laminated pad comprising: a first layer havingan exposed work surface; and a second layer overlaying and secured tosaid first layer said second layer including an intermediate manualgripping area.
 2. The pad of claim 1, wherein said second overlayinglayer comprises two adjacent portions, each portion being folded toprovide adjacent areas, one of said areas being adhesively attached to amating area of the other of said portions to provide said manualgripping area, and a remaining area of each of said portions beingadhesively attached to the opposite, unexposed surface of said firstlayer.
 3. The pad of claim 2 wherein said remaining areas of saidadjacent portions define a first periphery, and said first layer definesa second periphery, said first and second peripheries beingsubstantially coextensive with one another.
 4. The pad of claim 1wherein said exposed work surface comprises a polishing material.
 5. Thepad of claim 1 wherein said exposed surface comprises an absorbentmaterial.
 6. The pad of claim 1 wherein said exposed surface comprisesan abrasive material.
 7. The method of making a laminated pad having awork surface and a barrier surface comprising the steps of: providing acontinuous web of material having a work surface and an opposedsupporting surface; providing a continuous strip of carrier material forsupporting said continuous web; providing a first continuous web ofadhesive-backed material; folding said first web of adhesive-backedmaterial along two predetermined folding areas located longitudinallycoextensive of a length of said material to form two longitudinallycoextensive folded edges, wherein all of the exposed surfaces arepreferably adhesively coated; providing a second continuous web ofadhesive-backed material; overlaying and coupling said secondadhesive-backed material to a first side of said first, foldedadhesive-backed material length; coupling the supporting surface of saidcontinuous web of work surface material to a second side of said first,folded adhesive-backed material length to form a layered web; and diecutting said layered web into a predetermined pad configuration.
 8. Anapparatus for manufacturing a laminated pad comprising a first layerhaving an exposed work surface, a second layer overlaying and secured tosaid first layer, a said second layer including an intermediate manualgripping area, a said second overlaying layer comprising two adjacentportions, each portion being folded to provide adjacent areas, one ofsaid areas being adhesively attached to a mating area, the other of saidportions provides said manual gripping area, a remaining area of each ofsaid portions being adhesively attached to the opposite, unexposedsurface of said first layer, the apparatus comprising: rotatable supportmeans for supplying a continuous web of first layer material for saidlaminated pad; rotatable support means for supplying a continuouscarrier strip for supporting said first layer material; rotatablesupport means for supplying a first continuous web of material to beused for said second layer; rotatable support means for supplying asecond continuous web of material to be used for said second layer;means for folding said first continuous web along two predeterminedfolding areas located longitudinally coextensive a length of said firstweb to form two longitudinallly coextensive folded edges; means forlongitudinally moving said second web in a direction towards said foldedfirst web; and a rotatable anvil roller arranged to receive said foldedweb and said second web and compress each of said webs and said firstlayer toward said carrier strip.
 9. The apparatus of claim 8 whereinsaid means for folding comprises a first rotatable drive shaft forlongitudinally moving said first web, said shaft including a pair ofaxially spaced guide members for receiving and guiding said first webtherebetween; and a second rotatable drive shaft including a pair ofaxially spaced guide members for further receiving and guiding saidfirst web, the spacing between the guide members of said rotatable driveshaft being narrower than the spacing between said guide members of saidfirst drive shaft.
 10. The apparatus of claim 8 wherein said rotatablecutting tool includes a plurality of cutting knives, each of saidcutting knives having a pre-selected peripheral configuration.
 11. Theapparatus of claim 10 wherein said cutting knives are arranged to seversaid first and second layers through an area including at least onefolded edge.
 12. The method of making a laminated pad having a worksurface and a barrier surface comprising the steps of: providing acontinuous web of material having a work surface and an opposedsupporting surface; providing a first continuous web of adhesive-backedmaterial; folding said first web of adhesive-backed material along twopredetermined folding areas located longitudinally coextensive of alength of said material to form two longitudinally coextensive foldededges, wherein all of the exposed surfaces are preferably adhesivelycoated; providing a second continuous web of adhesive-backed material;overlaying and coupling said second adhesive-backed material to a firstside of said first, folded adhesive-backed material length; coupling thesupporting surface of said continuous web of work surface material to asecond side of said first, folded adhesive-backed material length toform a layered web; and die cutting said layered web into apredetermined pad configuration.
 13. An apparatus for manufacturing alaminated pad comprising a first layer having an exposed work surface, asecond layer overlaying and secured to said first layer, a said secondlayer including an intermediate manual gripping area, a said secondoverlaying layer comprising two adjacent portions, each portion beingfolded to provide adjacent areas, one of said areas being adhesivelyattached to a mating area, the other of said portions provides saidmanual gripping area, a remaining area of each of said portions beingadhesively attached to the opposite, unexposed surface of said firstlayer, the apparatus comprising: rotatable support means for supplying acontinuous web of first layer material for said laminated pad; rotatablesupport means for supplying a first continuous web of material to beused for said second layer; rotatable support means for supplying asecond continuous web of material to be used for said second layer;means for folding said first continuous web along two predeterminedfolding areas located longitudinally coextensive a length of said firstweb to form two longitudinallly coextensive folded edges; means forlongitudinally moving said second web in a direction towards said foldedfirst web; and a rotatable anvil roller arranged to receive said foldedweb and said second web and compress each of said webs toward said firstlayer.
 14. The apparatus of claim 13 wherein said means for foldingcomprises a first rotatable drive shaft for longitudinally moving saidfirst web, said shaft including a pair of axially spaced guide membersfor receiving and guiding said first web therebetween; and a secondrotatable drive shaft including a pair of axially spaced guide membersfor further receiving and guiding said first web, the spacing betweenthe guide members of said rotatable drive shaft being narrower than thespacing between said guide members of said first drive shaft.
 15. Theapparatus of claim 13 wherein said rotatable cutting tool includes aplurality of cutting knives, each of said cutting knives having apre-selected peripheral configuration.
 16. The apparatus of claim 15wherein said cutting knives are arranged to sever said first and secondlayers through an area including at least one folded edge.
 17. Alaminated pad comprising: a first layer having an exposed work surfaceand an opposite, unexposedsurface; and a second layer overlaying saidunexposed surface and secured to said first layer, said second layerincluding at least one intermediate manual gripping area.
 18. The pad ofclaim 17, wherein said second overlaying layer comprises at least twoadjacent portions, each portion being folded to provide adjacent areas,to provide said at least one intermediate gripping area, and a remainingarea of each of said portions being adhesively attached to the opposite,unexposed surface of said first layer.
 19. The pad of claim 18 whereinsaid remaining areas of said adjacent portions define a first periphery,and said first layer defines a second periphery, said first and secondperipheries being substantially coextensive with one another.
 20. Thepad of claim 17 wherein said exposed work surface comprises a polishingmaterial.
 21. The pad of claim 17 wherein said exposed surface comprisesan absorbent material.
 22. The pad of claim 17 wherein said exposedsurface comprises an abrasive material.
 23. A laminated pad comprising:a first layer having an exposed work surface and an opposite, unexposedsurface; and a second layer overlaying said unexposed surface andsecured to said first layer, said second
 24. The pad of claim 23,wherein said second overlaying layer comprises a plurality of adjacentportions; each portion being folded to provide a plurality of adjacentareas, to provide said manual gripping areas; and a remaining area ofeach of said portions being adhesively attached to the opposite,unexposed surface of said first layer.
 25. The pad of claim 24 whereinsaid remaining area of each of said adjacent portions defines a firstperiphery, and said first layer defines a second periphery, said firstand second peripheries being substantially coextensive with one another.26. The pad of claim 23 wherein said exposed work surface comprises apolishing material.
 27. The pad of claim 23 wherein said exposed surfacecomprises an absorbent material.
 28. The pad of claim 23 wherein saidexposed surface comprises an abrasive material
 29. The pad of claim 1,wherein said second overlaying layer comprises two adjacent portions;each portion being folded to provide adjacent areas to form said manualgripping area; and a remaining area of each of said portions beingadhesively attached to the opposite, unexposed surface of said firstlayer